BMW 535i 1987 Full Service Repair Manual

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🏷️ Basic Information Identification Make: BMW Model: 535i Year: 1987 Codes Chassis Code: E28 👋 Introduction Market Position Segment: Luxury Executive Sedan Target Audience: Enthusiasts, DIY mechanics, professional technicians, and...

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Type: Car

Vendor:

Sku: 425334

Tags: 1987 535i BMW Car Cars Misc

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

Luxury Executive Sedan

Target Audience:

Enthusiasts, DIY mechanics, professional technicians, and owners seeking in-depth knowledge of their vehicle.

Competitive Analysis

Competitors:

Mercedes-Benz W124 E-Class, Audi V8 Quattro, Jaguar XJ Series.

Key Features

Vehicle Strengths:

Performance, build quality, sophisticated engineering, driver-focused cockpit, rear-wheel drive dynamics.

Manual Value Proposition:

Empowers owners to perform complex maintenance and repairs, saving on labor costs and ensuring proper vehicle care.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive service, repair, diagnostic, and rebuilding procedures for the 1987 BMW 535i.

Specific Systems:

Engine, Fuel System, Cooling System, Exhaust System, Clutch, Transmission (Manual & Automatic), Drivetrain, Suspension, Steering, Brakes, Electrical System, Body & Chassis, Climate Control, Diagnostics.

Page Count

Estimated Pages:

1000+

Manual Type

Type:

Full Service & Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete teardown and rebuild procedures for the M30B34 engine, including cylinder head, block, crankshaft, connecting rods, pistons, timing components.

Engine Management:

Detailed information on the Bosch Motronic ML-S engine management system, including sensor diagnostics, actuator testing, and troubleshooting.

Fuel System:

Fuel injection system operation, fuel pump testing, injector diagnostics, fuel pressure regulation, and fuel tank maintenance.

Cooling System:

Radiator, water pump, thermostat, coolant flow, fan clutch, and heater core service procedures.

Exhaust System:

Catalytic converter, muffler, and pipe component identification, inspection, and replacement.

Transmission Manual:

Clutch assembly, gearbox overhaul, shift linkage adjustment, and driveshaft service for the Getrag 260 transmission.

Transmission Automatic:

Service and troubleshooting for the ZF 4HP22 automatic transmission, including fluid changes, adjustments, and common issues.

Drivetrain:

Rear axle service, differential overhaul, and CV joint maintenance.

Suspension:

Front and rear suspension component inspection, replacement, and alignment specifications (struts, shocks, control arms, bushings).

Steering:

Power steering system service, steering rack overhaul, and tie rod end replacement.

Brakes:

Front and rear brake system service (discs, pads, calipers, lines), ABS system diagnostics and repair.

Electrical System:

Comprehensive wiring diagrams, starter, alternator, battery service, lighting, and accessory system troubleshooting.

Body Chassis:

Body panel repair, door and window mechanisms, lock systems, and underbody protection.

Climate Control:

HVAC system service, A/C system recharge and leak detection, heater control valve replacement.

Procedures Included

Routine Maintenance:

Oil and filter changes, spark plug replacement, air filter replacement, coolant flushes, belt inspections and replacement.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and uncommon problems across all vehicle systems.

Repair Overhaul:

Detailed, step-by-step instructions for component removal, repair, rebuilding, and reinstallation.

Diagnostics:

Guidance on using diagnostic tools, reading fault codes (where applicable), and interpreting system behaviors.

Specifications Data:

Torque specifications, clearances, fluid capacities, electrical values, and performance data.

Technical Depth

Depth:

Expert level, covering everything from basic maintenance to complete engine and transmission rebuilds, including complex electrical diagnostics.

📊 Manual Specifications

File Format

File Type:

Searchable PDF

Searchability:

High (allows keyword searches within the document)

Print Quality

Resolution:

High-resolution scans of original factory documentation

Clarity:

Clear diagrams, schematics, and text for easy understanding.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

M30B34

Engine Type:

SOHC Inline 6-Cylinder

Displacement:

3.4 Liters (3430 cc)

Performance

Horsepower:

208 hp @ 5700 rpm

Torque:

220 lb-ft @ 4000 rpm

Bore X Stroke:

92.0 mm x 86.0 mm

Compression Ratio:

8.0:1

Fuel System

Fuel Delivery:

Bosch Motronic ML-S Fuel Injection

Fuel Type:

Unleaded Gasoline (Premium)

Ignition System:

Distributorless Electronic Ignition (EI)

🔧 Transmission

Standard

Type:

Getrag 260 5-Speed Manual Transmission

Optional

Type:

ZF 4HP22 4-Speed Automatic Transmission

Features

Clutch:

Hydraulically Actuated Single Dry Plate Clutch

Drivetrain:

Rear-Wheel Drive (RWD)

Final Drive Ratio:

3.25:1 (Typical for Manual, varies)

📐 Dimensions

Exterior

Length:

188.3 in (4783 mm)

Width:

69.4 in (1763 mm)

Height:

55.7 in (1415 mm)

Wheelbase:

104.3 in (2649 mm)

Front Track:

57.9 in (1471 mm)

Rear Track:

57.5 in (1460 mm)

Weights

Curb Weight Manual:

Approx. 3,505 lbs (1590 kg)

Curb Weight Automatic:

Approx. 3,593 lbs (1630 kg)

Gross Vehicle Weight Rating Gvwr:

Approx. 4,586 lbs (2080 kg)

🛡️ Safety Features

Ratings

Fmvss Compliance:

Meets all applicable Federal Motor Vehicle Safety Standards (FMVSS) for 1987.

Active Features

Anti-lock Braking System (ABS) standard on 535i

Suspension Design:

Independent front and rear suspension for stable handling.

Passive Features

Seatbelts:

Three-point inertia-reel seat belts front and rear.

Body Structure:

Reinforced safety cage, crumple zones.

Steering Column:

Collapsible steering column.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM Cassette player with optional premium sound system.

Climate Control:

Manual or automatic climate control (ECC - Electronic Climate Control) depending on trim.

Driver Assistance

Cruise Control:

Standard cruise control system.

Trip Computer:

Optional trip computer with basic functions.

Connectivity

Connectivity Features:

No modern connectivity features like Bluetooth or USB ports; analog systems.

🔧 Maintenance

Service Intervals

Oil Change:

Every 3,000-5,000 miles or 6 months (depending on driving conditions and oil used).

Coolant Flush:

Every 2 years or 30,000 miles.

Transmission Fluid Manual:

Inspect at 30,000 miles, change as needed or at higher mileage intervals (e.g., 60,000 miles).

Transmission Fluid Automatic:

Check periodically, change every 30,000-50,000 miles.

Spark Plugs:

Replace every 30,000 miles (refer to manual for specific type).

Fluid Specifications

Engine Oil:

API SG or higher, SAE 15W-40 or 20W-50 (check owner's manual for specific recommendation based on climate).

Coolant:

BMW Blue Antifreeze (Ethylene Glycol based) mixed 50/50 with distilled water.

Transmission Fluid Manual:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 Gear Oil.

Transmission Fluid Automatic:

BMW ATF Dexron II or equivalent.

Brake Fluid:

DOT 3 or DOT 4.

Power Steering Fluid:

ATF Dexron II or equivalent.

Known Issues

Engine Oil Leaks:

Common leaks from valve cover gasket, oil pan gasket, and front/rear main seals.

Cooling System:

Degradation of rubber hoses, radiator tank cracking, thermostat failure.

Electrical System:

Corrosion in fuse box, failing fuel pump relay, headlight switch issues, wiring harness degradation.

Suspension:

Worn control arm bushings, sagging springs, worn shock absorbers.

ABS Sensors:

Potential failure of ABS wheel speed sensors leading to ABS warning light.

📚 Vehicle History

Brand Heritage

Bmw Legacy:

BMW's reputation for performance, engineering excellence, and sporty driving dynamics.

Model Evolution

E28 Generation:

The E28 generation (1981-1988) represented a refinement of the E12 chassis, known for improved aerodynamics and technology.

535I Positioning:

The 535i was the performance-oriented variant of the E28 5 Series, bridging the gap between the 528e and the M5.

Production

Production Years E28:

1981-1988

Manufacturing Location:

Germany

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The E28 5 Series, including the 535i, was a frequent recipient of Car and Driver's '10 Best' list during its production years, recognized for its driving dynamics and engineering.

Ratings

General Reputation:

Highly regarded by automotive critics and enthusiasts for its blend of performance, luxury, and build quality.